Drive electrodes for microfabricated torsional cantilevers

This application claims the benefit of U.S. Provisional Application No. 60/001,296, filed Jul. 20, 1995, the disclosure of which is incorporated herein by reference, and is a continuation-in-part of U.S. application Ser. No. 08/683,929, filed Jul. 19, 1996, the disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates, in general, to microelectromechanical structures (MEMS), such as torsional cantilevers, to actuators for MEMS devices, and to methods for fabricating such structures. More particularly, the invention relates to high aspect ratio, single crystal silicon MEMS devices, such as a torsional cantilever having a cantilever moment arm mounted on a torsional support beam, to actuators incorporating multiple interleaved comb drive fingers which are energizable to actuate the cantilever, to a novel actuator structure, and to a process for fabricating such structures which is compatible with processes for making conventional silicon integrated circuits.

Since their development in the early 1980s, scanning probe microscopes have become important tools for surface analysis and surface modification. The unique applications of scanning probe microscopes include imaging and manipulating single atoms, measuring forces on the atomic scale, and performing nm-scale lithography. At the center of the family of scanning probe microscopes are the scanning tunnelling microscope (STM) and the atomic force microscope (AFM). These macroscopic scanned probe instruments, for the most part, use large piezoelectric actuators to position a sensing tip or a probe in three dimensions (xyz) and thus to provide relative motion between the tip and a sample surface. However, the size of these microscopic instruments limits their performance, for the mass of the tip-actuator structure produces low resonant frequencies and low scanning rates. More importantly, these large instruments cannot be easily integrated into arrays for high speed scanning and atom manipulation, for information storage, or for high throughput, nm-scale lithography systems.

A cantilever of some sort is often used in macroscopic force microscopy to monitor the variations in forces which represent the interaction between a tip and a sample. In such cases, the cantilever is usually a silicon nitride "V" cantilever which, for example, may be 0.6 to 2 micrometers thick, may be 100 to 200 micrometers long, and which may have a spring constant of between about 0.03 and 3 N/m for contact mode imaging. See, for example, T. R. Albrecht et al., J. Vac. Sci. Technol. A8, 3386 (1990). For non-contact mode imaging, the cantilever may be silicon with a spring constant of about 1 to 100 N/m, as described by Wolter et al., J. Vac. Sci. Technol. B9, 1353 (1991). In order to obtain a high degree of sensitivity, a low spring constant k and a high Q is needed for such cantilevers, and attempts have been made to accomplish this through the use of thin films. However, it is necessary to make the cantilever very thin in order to achieve a low spring constant with a thin film; for example, magnetic resonance force detection has been performed using a cantilever (without an integrated tip) that was only 900 Å thick, and which had a spring constant of 10^-3 N/m. However, the fabrication and use of such thin cantilevers poses many problems, including the problem of tip integration, problems with internal stress, and problems in making electrical connections and in amplifying the resulting signals.

For many years, torsion has been used as a technique for highly sensitive measurements of force interactions; for example, measurement of Coulomb's torsional balance for electrostatic forces and Cavendish's balance for gravitation. Furthermore, torsional resonators have been used as high-Q resonators to study a variety of physical properties, such as dissipation and visoelasticity. Such devices have been widely used because cantilevers, resonators, or balances can be made symmetric with respect to their center of mass, with the result that lateral vibrations of the support do not couple to the torsional mode of the sensor device. In the case where the measuring device includes a spring, lateral modes of the spring can be made much stiffer than the torsional mode without affecting the torsional behavior, thus making torsional measurements desirable.

Torsional cantilevers are known to provide a viable option in scanning force microscopy. However, such cantilevers have, in the past, been assembled by hand, using cleaved pieces of silicon, carbon fibers or tungsten wire, and epoxy. Such devices did not incorporate integrated tips and, although microfabricated cantilevers have been demonstrated, such devices exhibited a lateral stiffness which was as soft as, or softer than that of a V-shaped cantilever. The lack of sufficient lateral stiffness can result in unwanted "stick-slip" behavior as the cantilever is scanned across samples.

SUMMARY OF THE INVENTION

The present invention is directed to microelectromechanical structures (MEMS) which incorporate capacitive actuators, or drivers, for producing mechanical motion, and more particularly to an improved comb-type actuator structure which can be used with a wide range of MEMS devices to provide improved control of the motion of such devices. The comb-type structure consists of high aspect ratio MEMS beams fabricated as interleaved fixed and movable capacitor fingers. The beams may be electrically conductive or may carry a conductive layer so that application of a voltage between adjacent fingers produces an electrostatic force which tends to produce relative motion of the fingers. Furthermore, application of an external mechanical force which causes relative motion of the fingers produces a corresponding change in the field between the fixed and movable fingers and this change can be measured by suitable electrical circuitry connected to the fingers.

In accordance with the invention, the fixed and movable MEMS actuator fingers used to form comb-type capacitive actuator structures are of different heights, and such asymmetry has been found to produce numerous advantages over prior comb-type actuators. For example, it has been found that an asymmetric finger height increases the force produced in a vertical, out-of-plane direction between adjacent fingers, providing improved vertical actuation and motion control in MEMS devices to which the fingers are attached. The asymmetric configuration also provides control of the total amount of out-of-plane static deformation that occurs in MEMS structures, and allows actuators so constructed to produce vertical motion even in the absence of a substrate ground plane.

In a preferred form of the invention, the actuator is fabricated on a substrate as a part of a MEMS structure whose motion is to be controlled, or measured. The movable actuator fingers form electrodes, and these fingers and the substrate are electrically grounded. A potential, which may be variable, is applied to the fixed finger electrodes. The fixed fingers have a greater height than the movable fingers, causing the electric field produced by the applied potential, between the electrodes to be vertically asymmetric. This asymmetric field creates a vertical force which causes the movable finger electrodes to shift vertically with respect to the fixed finger electrodes. The vertical force can be used to generate static displacements of MEMS devices, to produce vibrational motion, or to otherwise control the motion of the device or structure to which the actuator is connected. Conversely, motion of the device or structure produced by external forces produces relative motion of the actuator fingers which changes the electrostatic field, and such changes are a measure of the applied external force.

The present actuator may be used, in one aspect of the invention, to drive, and to measure the motion of, MEMS structures, such as a torsional cantilever which is microfabricated for reduced size to increase its resonant frequency and thereby to increase its scanning speed. Such a microfabricated cantilever may incorporate an integrated tip so that it is particularly adapted to provide highly sensitive detection of forces, and both the cantilever and the drive actuators preferably are integral with a substrate which may incorporate conventional integrated circuits to which the actuator as well as the cantilever and/or its tip may be electrically connected.

In a preferred form of this invention, MEMS devices are fabricated from a substrate material of single crystal silicon, with the cantilever and integral actuator structures preferably being fabricated by the single crystal reactive etch and metallization (SCREAM-I) process described in copending U.S. patent application Ser. No. 08/312,797 filed Sep. 27, 1994 of Kevin A. Shaw, Z. Lisa Zhang, and Noel C. MacDonald, now U.S. Pat. No. 5,719,073, issued Feb. 17, 1998, the disclosure of which is hereby incorporated herein by reference. This fabrication process allows integration of an actuator structure and any desired movable structure on a single crystal silicon substrate which may carry pre-existing integrated circuits. The movable structure may be a cantilever with an integral submicron tip for use, for example, in scanning surfaces to be measured in scanning probe microscopy, or in other applications, with the actuator providing the force and the precision of motion required for such uses.

The actuators, or motion control devices, preferably are fabricated as capacitors for producing and/or for controlling the motion of a MEMS structure. In the case of a cantilever structure, the actuators preferably are arranged and connected to produce motion in x, y, and z directions with respect to the axis of the cantilever, with such capacitors also being available to measure tip motion in response to forces to be detected. The process of the present invention also permits incorporation of other sensors, such as piezoresistive devices, diodes, or transistors within the cantilever structure for use, for example, in detecting motion or in amplifying electrical currents detected by the tip. The integration of all of these features produces a scanning torsional cantilever that is extremely compact, which requires no external deflection sensor, and which is suitable for use in a variety of atmospheres and temperatures, as well as for use in dense array architectures of scanned probe instruments for information storage and molecular or atomic manipulation.

The torsional cantilever structure is a basic building block for micromechanical scanning probe microscopes, and can be fabricated with an integrated tip in a 100 μm×100 μm square area. The structure includes a torsional support beam which is secured at each of its ends to a substrate; preferably, the support beam is integrally formed with the substrate. A sensor arm, or cantilever moment arm, consisting of a rigid grid of single crystal silicon beams is microfabricated integrally with the support beam, and extends generally horizontally outwardly from the beam in cantilever fashion, the beam support and the sensor arm lying in a horizontal x-y plane and perpendicular to each other. The outermost, or free end of the sensor arm carries a sensor tip which interacts with a sample to be measured.

The movable cantilever may be made to pivot about its support beam in a vertical z direction by a potential applied between fixed electrodes fabricated on the substrate beneath the cantilever structure and corresponding electrodes on the cantilever. The structure may also incorporate interdigitated comb capacitor structures to provide controlled motion of the cantilever in the x-y plane or in other directions dependent on the location of the comb structures. Pivotal motion of the cantilever about the torsional support beam provides the out-of-plane motion required to enable the tip to track a surface. If desired, a small xy scanner may be integrated into the cantilever structure for precise lateral positioning of the tip.

Forces applied to the tip, for example in the vertical (z) direction, deflect the tip, and this motion is transferred by the cantilever sensor arm to the support beam in the form of a torsional force applied about the horizontal axis of the support beam. This torsional force can be measured in a variety of ways to provide an accurate measure of tip deflection and thus of the applied force. For example, the relative motion of interdigitated actuator fingers, or the motion of an electrode on the cantilever with respect to an underlying electrode, can produce a change in capacitance between the electrodes which can be measured. Deflection can also be measured by a piezoresistor in or on the support beam. The piezoresistor can be produced, for example, by implanting an n-type region into a p-type substrate or implanting a p-type region into an n-type substrate. The doped region forms a resistance which changes due to stress produced in the support beam by rotation of the cantilever arm.

The measurement of rotation can also be accomplished by another stress-sensitive device based on the piezojunction effect. In this case, a sensor diode is formed by implanting an n-type region in the p-type substrate silicon at the junction of the torsional support beam with a fixed mesa on which the beam is mounted. Contacts are made to this implanted region and to the adjacent substrate. Stress in the support beam causes a change in current through this diode, and changes in the current can be measured.

The cantilever moment arm structure of the invention can be utilized whenever out-of-plane or rotational devices such as force sensors are required. Such a movable device may be used, for example, in an accelerometer, wherein an asymmetric design, with slightly more mass on one side of the support beam for the cantilever than on the other, provides a balanced structure which will be sensitive to acceleration in directions out of the plane of the cantilever. The movable device can also be used in force microscopy by employing a symmetric design which balances the applied force so that the device will be highly sensitive to changes in a force acting on one side of the support beam for the cantilever, but not on the other.

By integrating a tip on the free end of the cantilever moment arm in a microscope, the torsional cantilever becomes a tip-to-surface force sensor in a scanning force microscope. The out-of-plane motion, or torsional cantilever motion (in the z direction), also enables the tip to track surface topography. If desired, the cantilever may carry a mirror or an interferometer to provide accurate measurement of out-of-plane or rotational motion, or one or more of the sensors described above can measure and/or control this motion.

With the torsional cantilever beam established as a building block, an array of beams can be fabricated, wherein cantilevers can be provided at 100 μm intervals to provide, for example, a 10×10 array of cantilevers in a 1 mm by 1 mm square area. Such an array allows an entire 1 mm by 1 mm sample to be scanned for imaging or manipulation by moving the support mechanism only 100 μm in x and y directions.

The array can be made in several configurations. For example, torsional cantilevers can be made individually movable in the z direction while the sample is scanned in x and y directions. Alternatively, the cantilevers can be fabricated to be movable in the z direction as part of a micromechanical structure that is scannable in the x direction, with the sample being scannable in the y direction. In another configuration, the z cantilevers can be fabricated as part of a micromechanical stage that is scannable in x and y directions, with the sample remaining stationary. The sample can be a chip with a bare surface or a compliant surface, or can be an active MEM device. Alternatively, the sample can be placed on or bonded to a chip which carries an array of microscanned probe devices, wherein the torsional cantilever elements which make up the probe provide enough out-of-plane (or z-direction) motion to allow the tips to contact the surface. To facilitate this, sample support pillars or posts are fabricated on the chip which carries the array, with the pillars having the same height as, or being a little taller than, the tips.

A large number of electrical connections are required in an array of cantilevers to carry control signals for individually moving the cantilever arms or for carrying sensor output signals from each arm. Transistors for switching among various devices can reduce the number of connections, and such switches can be in the form of normal planar IC transistors fabricated on the silicon substrate. Metal pathways along the substrate provide the necessary connections. Suspended transistors in the silicon beams can also be used for switching, amplification, and logic, and electrical isolation can be provided by oxide segments in the beams.

The cantilevered arms and arrays of such arms can be used in a wide range of applications. In addition to scanning of images and the manipulation of surfaces at atomic and near-atomic scales, the devices and arrays of the invention can be used for high density information storage, in the range of a terabit per cm², for molecular manipulation instruments, for field emission (e-beam) instruments, and for microlithographic or micromachining tools.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing, and additional objects, features and advantages of the present invention will become apparent to those of skill in the art from the following detailed description of preferred embodiments thereof, taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a partial perspective view in diagrammatic form of a torsional cantilever device in accordance with the present invention;

FIG. 2 is a top plan view of the cantilever device of FIG. 1;

FIGS. 3(a) through 3(h) illustrate a process for fabricating sensor tips on the device of FIG. 1;

FIGS. 4(a) and 4(b) are diagrammatic illustrations of a metallization process-used in the device of FIG. 1;

FIG. 5 is a partial, enlarged view of the cantilever structure of FIGS. 1 and 2;

FIG. 6 is an enlarged, partial view of the torsional support beam for the device of FIG. 1;

FIG. 7 is a graphical illustration of curves representing the relationship of effective spring constant to cantilever length for different cantilever cross-sectional widths "a" each having a cantilever cross-sectional height "b" of 10 μm;

FIG. 8 is a top plan view of a second embodiment of the cantilever device of the present invention;

FIG. 9 is a top plan view of a third embodiment of the cantilever device of the present invention, utilizing torsion control electrodes;

FIG. 10 is a cross-sectional view taken along lines 10--10 of FIG. 9;

FIG. 11 is a fourth embodiment of the cantilever device of the present invention, utilizing comb-type capacitive sensors for motion sensing and compensation;

FIG. 12 is a fifth embodiment of the device of the present invention, utilizing comb-type capacitive actuators or sensors;

FIG. 13 is a partial, enlarged perspective view of a modified comb-type actuator or sensor for the device of FIG. 12;

FIG. 14 illustrates a first alternative version of the comb-type actuator or sensor of FIG. 13;

FIG. 15 illustrates a second alternative version of the comb-type actuator or sensor of FIG. 13;

FIG. 16 is a sixth embodiment of the cantilever device of the present invention, combining the features of FIGS. 13 and 14;

FIG. 17 is a diagrammatic illustration of the use of the torsional cantilever device of the present invention in an atomic force microscope;

FIG. 18 is a photomicrograph of the torsional cantilever device of the present invention incorporated in an capacitor-driven xy stage configuration;

FIG. 19 is a diagrammatic illustration of an array of cantilevered sensors mounted for motion in an xy plane, with individual cantilevers being movable in the z direction;

FIG. 20 is an enlarged, partial top plan view of a torsional cantilever device incorporating piezoresistive sensors;

FIG. 21 is a cross-section along lines 21--21 of FIG. 20;

FIG. 22 is an enlarged, partial top plan view of a torsional cantilever device incorporating diode sensors;

FIG. 23 is a cross-sectional view taken along lines 23--23 of FIG. 22;

FIG. 24 is a diagrammatic illustration of the electric field lines between movable and fixed electrodes and a substrate in a comb-type actuator;

FIG. 25 is a plot of levitation torque as a function of angle for the configuration of FIG. 24;

FIG. 26 is a diagrammatic perspective illustration of a comb-type actuator having asymmetric sets of interdigitated fingers in accordance with another embodiment of the invention;

FIG. 27 is a diagrammatic view taken along line 27--27 of FIG. 26, illustrating the electric field lines between adjacent fingers of the asymmetric comb-type actuator of FIG. 26, wherein fingers of a movable set of fingers have a height less then the height of the fingers of a fixed set of fingers;

FIG. 28 is a plot of levitation torque as a function of angle for the configuration of FIG. 27.

FIG. 29 is a plot of out-of-plane static deflection for symmetric electrodes as a function of the voltage applied to adjacent fingers in the device of FIG. 24;

FIG. 30 is a plot of static deflection of torsional cantilever array elements as a function of applied voltage when scaling the width (a) of torsional support beams; and

FIG. 31 is a plot of out-of-plane static deflection of two microelectromechanical devices with movable and fixed electrode fingers of different heights.

DESCRIPTION OF PREFERRED EMBODIMENTS

Turning now to a more detailed consideration of the present invention, there is illustrated in FIG. 1 a perspective view of a microfabricated, highly sensitive force detecting torsional cantilever device 10 incorporating an elongated torsionally-mounted microelectromechanical (MEM) cantilever moment arm generally indicated at 12. This device has a wide range of applications, but will be described herein for convenience as being used as a force sensor in scanning probe microscopy. The cantilever moment arm portion 12 is mounted at a first, or near end 14 to the center of a laterally extending torsional support beam 16. In the illustrated embodiment, the opposite ends of the beam 16 are supported on, and preferably are integral with, a substrate 18 as at support mesas 19 and 20. The moment arm 12 is integral with beam 16 and in its preferred form is a grid of longitudinal and lateral beams, as illustrated in FIG. 1, the arm extending from a near end 14 generally horizontally forwardly from the support beam 16 to a far, or distal, end 21 along a longitudinal axis 22 (FIG. 2) which is perpendicular to beam 16. An upwardly-extending, or generally vertical, nanometer-scale sensing tip 23 is formed on the distal end 21 of the cantilever moment arm in the preferred form of the invention. This sensing tip is generally conical, tapering upwardly and inwardly to an extremely small diameter, on the order of one atom, at its end 24. The moment arm 12 and support beam 16 lie in an x-y plane, with tip 23 extending perpendicularly to the plane, in a z direction.

Also mounted on lateral support beam 16, but on the opposite side thereof from moment arm 12, is a counterweight 26 which is also fabricated as a grid of longitudinal and lateral beams (not shown in FIG. 1), and which is of sufficient size and weight to produce a counterbalancing mass for the cantilevered moment arm so as to make the arm 12 more sensitive to, and responsive to, forces applied to tip 23. The counterweight 26 serves as an extension of cantilever moment arm 12 so that arm 12 and counterweight 26 rotate together about a lateral axis 27 (see FIG. 2) of the beam 16. Axis 27 lies in the x-y plane of arm 12 and beam 16, with axis 27 being perpendicular to the longitudinal axis 22 of arm 12. Rotation of arm 12 and weight 26 occurs upon application of vertical forces in the direction of arrow 28 in FIG. 1; that is, upon application of forces having a vector in the z direction to the tip 23.

The torsional cantilever device 10, which includes the moment arm 12, the lateral torsional mounting beam 16, the tip 23, and the counterweight 26, is fabricated by the SCREAM-I process described in the aforesaid U.S. Pat. No. 5,719,073, discussed above. This process includes a reactive ion etching process for fabricating suspended, released, single crystal silicon microelectromechanical (MEM) structures, with feature dimensions as small as 250 nm and with arbitrary structural orientation with respect to the crystalline structure of the single crystal silicon wafer or substrate 18. During the fabrication process, the torsional cantilever structure 10 is released from the underlying substrate so that it is mechanically spaced from, is supported over, and is generally parallel to, the underlying substrate. The cantilever structure 10 is connected to the substrate only at support regions 30 and 32, where the lateral support beam 16 intersects and is integral with mesas 19 and 20 formed during the fabrication process, or is integral with the sidewalls of a cavity formed in the substrate 18. The cantilever device 10 is conveniently referred to as a released structure.

During the SCREAM-I fabrication process, the beams which make up moment arm 12, support beam 16, and counterweight 26 are lithographically defined in a single etch mask and the regions surrounding the defined structure are removed from the substrate by reactive ion etching (RIE) to form surrounding trenches which together produce a cavity 34 having vertical walls 36 in the substrate 18. The cavity also surrounds the support mesas 19 and 20 which are formed in the substrate, as illustrated. Thereafter, a second RIE step undercuts and releases the defined structure and in addition undercuts the support mesas and surrounding substrate mesa. The cavity 34 thus incorporates a generally vertical side wall 36, which surrounds the cavity 34 in which cantilever device 10 is located and a floor 38 which underlies the cantilever and which, preferably, lies in a horizontal (x-y) plane below and substantially parallel to the cantilever 10. The side wall 36 surrounding the cavity 34 defines not only the support mesas 19 and 20, but also a substrate mesa region illustrated at 40 in FIG. 1. The side wall 36, as well as the walls of the mesas 19 and 20, are undercut, as illustrated at 41, during the release step. The substrate mesa region 40 may incorporate one or more integrated circuits, such as those generally indicated at 42 and 44 in FIG. 2, which may be fabricated in conventional manner prior to the formation of the cantilever 10.

In the SCREAM-I process, a metal layer 46 may be deposited on the released structure and the surrounding substrate. This metal layer is discontinuous at the trenches to separate the metal on the released elements from the metal on the substrate both mechanically and electrically. Furthermore, the undercut portions 41 prevent metal deposited on the floor of the cavity from being electrically connected to the metal on the mesas.

The SCREAM-I process is a low temperature process which is compatible with conventional integrated circuit processes, and thus with preexisting integrated circuits on the substrate. Thus, a substrate, or wafer, may first be processed in conventional manner to provide integrated circuits which are to be used to control or to sense a cantilever moment arm structure. A space is left on the wafer for subsequent fabrication of the microelectromechanical structure of the present invention by the SCREAM-I process. This process will not damage the integrated circuits, and the SCREAM-I process provides suitable metalization to permit selected electrical connection to, and interconnection between, the cantilever structure and the preexisting integrated circuits.

In the preferred form of the invention, the high aspect ratio sensor tip 23 is formed before the above-described cantilever fabrication steps. In one process for making the tip illustrated in FIGS. 3(a)-3(b), an n-type, P-doped, 18-40 ohm-cm, (100) oriented single crystal silicon substrate is subjected to ion implantation by an As dose of 5×10¹⁴ /cm² at 30 keV to form an n⁺ layer. A dielectric stack consisting of a 20 nm layer of thermal oxide, a 150 nm layer of LPCVD nitride and a 600 nm layer of PECVD oxide is formed on the top surface of the substrate, as illustrated in FIG. 3(a), and a 700 nm film of KTI-OCG photoresist is patterned and exposed in a GCA 4800 DSW wafer stepper, to produce a resist pattern (FIG. 3(a)). The resist pattern is transferred to the dielectric stack by a CHF₃ reactive ion etch (RIE) to produce a dielectric mask, as illustrated in FIG. 3(b). An SF₆ RIE etch then produces a silicon cone under the dielectric mask. In one example, a 4 sccm SF₆ /2 sccm O₂ etch in a chamber having a pressure of 5 mTorr and under a DC bias of -300 V with an etch time of 5 minutes produced a 1.5 μm high circular cone underneath a 600 nm diameter dielectric mask. A 100 nm silicon dioxide layer is then thermally grown on the exposed silicon surface (FIG. 3(c)).

The foregoing was followed by a CHF₃ -RIE to etch any oxide on the horizontal surfaces (see FIG. 3(c)), and a Cl₂ -RIE vertical etch produced a high aspect ratio (height to diameter ratio of at least about 10 to 1) silicon post, as illustrated in FIG. 3(d) This etch utilized a 50 sccm Cl₂ /2 sccm BCl₃ etch at a chamber pressure of 20 m Torr and a DC bias of -400 V. Thereafter, thermal oxidation was used to sharpen the tip (FIG. 3(e)). A typical sensor tip may have a height of about 10-20 μm, a diameter of about 1 μm, and a tip radius of about 10 nm.

If the tip is to be used as a force sensor or for similar purposes, the foregoing steps are followed by the above-described SCREAM process to fabricate the cantilever 10. However, in some cases it is desirable to utilize the tip as a field emitter, in which case a self-aligned electrode is formed in accordance with FIGS. 3(f) through 3(h). In this procedure, a metal contact window is opened through the oxide layer, followed by an As implant at 30 keV, 5×10¹⁵ /cm², and annealing at 1000° C. for 30 sec. Thereafter, a sputter deposition of TiW covers the surface of the substrate and the tip (FIG. 3(f)). A planarizing layer of KTI-OCG is spun on and baked at 90° C. (FIG. 3(g)), and an O₂ plasma etch removes the photoresist until the TiW above the apex of the tip is exposed (FIG. 3(g)). Finally, an SF₆ -RIE etch of the TiW layer exposes the end of tip 23, with the tip being surrounded by a closely-spaced TiW electrode. Thereafter, the SCREAM-I process is used to fabricate the cantilever 10.

The forces which are to be detected by the torsional cantilever 10 produce motion in the z-direction, as noted above, which is translated by tip 23 and moment arm 12 into a torsional motion about the lateral axis of rotation 27 corresponding to the lateral torsional beam 16. Vertical motion of tip 23 thus produces a torsional force on beam 16 in the direction of arrow 50 (FIG. 1), and this motion can be measured by a suitable sensor, such as a plate capacitor, sensors such as multiple comb-type capacitors, by piezoresistors, or to devices, such as transistors or diodes. For example, a capacitor for sensing vertical motion of moment arm 12 may be provided by formation of a metal electrode 54 on the floor 38 of the cavity 34 below arm 12, as well as an electrode 54' on the floor of the cavity under the counterweight 26. These electrodes may be part of the metal layer 46 deposited on the device during the SCREAM process described above, but are electrically isolated from the metal on the arm 12 and counterweight 26, as described above. The electrodes 54, 54' and layer 46 form opposed, spaced capacitive plates which are connected through metal connectors formed by patterning the metal layer, or are connected by wires such as wires 55 bonded to the electrode and to circuits, such as circuits 42 or 44.

The capacitance between the metal layer 46 on moment arm 12 and the underlying metal layer 54 and the capacitance between the metal layer 46 on counterweight 26 and the underlying metal layer 54' varies in opposite directions as the arm and the counterweight rotate about beam 16 upon the application of a force to tip 23. The rotation of moment arm 12 thus produces a differential change in capacitance which can be measured with great accuracy to provide a highly sensitive detection of the relative motion between arm 10 and the substrate 18, and thus of the motion of tip 23.

The metal capacitor electrodes 54 and 54', preferably, are fabricated by sputtering metal, such as aluminum, onto the substrate 18 containing the released torsional cantilever structure, and then evaporating aluminum, at an angle sufficient to provide metal coverage under the beams as at 56 in FIGS. 4(a) and 4(b), utilizing, for example, a rotating stage 57. FIG. 4(b) is an enlarged partial view of the substrate, illustrating how the metal 56 passes suspended elements such as individual beams 58 making up the cantilever structure to reach the floor 38 of the cavity in which the beams are located. The metal is then patterned using conventional photolithography and reactive ion etching to shape the electrodes and to provide surface electrical connections or connector pads for interconnecting the electrodes and adjacent circuitry.

In place of, or in addition to, the capacitive electrodes 54 and 54' on the floor of the cavity, comb-type actuator or sensor elements may be provided between the released torsional cantilever structure and the substrate to produce or to sense motion of the cantilever. Such comb-type actuators or sensors will, for convenience, be referred to herein as a sensor or as an actuator, but it will be understood that an actuator may function as a sensor, and vice versa. Such actuators may take several forms, as will be described below, and in one form may incorporate partially oxidized silicon beams fabricated by the process described in copending U.S. patent application Ser. No. 08/383,524 of Noel C. MacDonald and Ali Jazairy, filed Feb. 3, 1995, and entitled "Masking Process for Fabricating Ultra-High Aspect Ratio, Wafer-Free, Micro-Opto-Electromechanical Structures", now U.S. Pat. No. 5,628,917, the disclosure of which is hereby incorporated herein by reference.

In the embodiment of the invention illustrated in FIGS. 1 and 2, the moment arm 12 has a stepped shape of decreasing width and is made up of a grid of individual longitudinal and lateral beams 58 having high aspect ratios to provide the desired rigidity, and thus the high spring constant, needed to provide the desired accuracy of measurement of applied forces at tip 23. Near the base 14 of the moment arm 12, the arm is formed with a relatively wide region 60 which steps down at shoulder 62 to a second, slightly narrower region 64 at a selected distance along axis 22 from the base 14. Region 64, in turn, steps down at shoulder 66 to a still narrower region 68 and again steps down at shoulder 70 to the narrowest region 72 on which the tip 23 is mounted at progressively distances along axis 22. The wide, stepped-down, elongated shape gives lateral stability to the moment arm 12 (in the x-y plane) so that it is relatively unaffected by lateral vibrations. The height of each beam, and thus of each region of the moment arm, as indicated by arrow 74, is sufficient to provide vertical rigidity, and to provide a relatively large height to width ratio, or aspect ratio, for each component beam in the structure. It will be apparent, of course, that numerous variations of this overall shape of the moment arm may be used while still providing the desired stability and rigidity for the arm.

In the preferred embodiment, the arm 12 is secured to the torsional support beam 16 by a plurality of longitudinally extending connector beams 76, 77, 78, and 79 (FIG. 1). These connector beams are formed integrally with the moment arm 12 and with the torsional beam 16, and have substantially the same height 74 as the arm 12 so as to maintain vertical rigidity and a high spring constant. Each of the connector beams 76-79, preferably, is thin, for light weight, with a cross-section having a high aspect ratio; that is, an aspect ratio of about 10 or 20 to 1.

In the illustrated embodiment of the invention, the counterweight 26 is fabricated as a generally rectangular structure having a height approximately equal to the dimension 74 and having an axial length along axis 22 and a lateral width parallel to axis 27 sufficient to provide a mass which will counter-balance the mass of the arm 12. The counterweight 26 is mounted on support beam 16 by connector beams 80-83 which are mounted on, and which preferably, are integral with, the transverse support beam 16, as well as being integral with the counterweight 26. The beams 80-83 are similar to and correspond to beams 76-79, and thus have relatively high aspect ratios to provide the required stability for the counterweight 26 and to provide a high spring constant mounting for the counterweight which will permit accurate measurement of forces applied to tip 23.

Although the metal layer 46 applied to the surface of the cantilever 10 is illustrated in FIG. 1 as a solid covering for the moment arm and counterweight structure, a preferred form of the invention is illustrated in FIGS. 2 and 5. As diagrammatically illustrated in FIG. 2, and as best seen in FIG. 5, the moment arm 12 and the counterweight 26 are formed as an open grid or lattice work of thin, high aspect ratio beam segments, such as the segments 58 illustrated in an enlarged view in FIG. 5. Only a small number of such beam segments are illustrated in FIG. 1 for clarity; however, as diagrammatically illustrated in FIG. 2, the cantilever structure 10, preferably, is made up of a large number of closely spaced beam segments.

The entire structure of cantilever moment arm 12, torsional support beam 16, counterweight 26, and connector beams 76-83 is fabricated from single crystal silicon using the SCREAM-I process. Each beam segment thus has a high aspect ratio on the order of about 10 to 1, with the segments being released from, and spaced from, the underlying substrate floor 38 and spaced from the side walls 36. The ends of beam 16 are mounted to mesas 19 and 20 at connecting regions 30 and 32, where the lateral torsional support beam 16 is integral with the substrate to support the cantilever structure 10. The thin, tall beam segments provide a high spring constant and high rigidity in the vertical direction and are interconnected to provide a laterally rigid structure, as noted above.

As described above, vertical motion of the arm 12 in the direction of arrow 28 (FIG. 1) produces a twisting motion, or torsional motion, as indicated by arrow 50, about the axis 27 of support beam 16 (see FIG. 6). The support beam has a high aspect ratio rectangular cross section, with a spring constant: ##EQU1## where I=ab² /12 is the second moment of area, a is the width of the beam, b is the height of the beam, and L_C is the length of the moment arm 12 which produces the torsional force (see FIGS. 2 and 6). For a rectangular beam experiencing a torque (T) the angle of rotation (θ) about its central axis 27 (in the direction of arrows 50)is: ##EQU2## where L_T is the length of the beam 16 between the mounting point 32 and the nearest support beam 79 which produces the torsional force; G is the shear modulus of rigidity of the material; and β is a coefficient determined by the aspect ratio b/a. For silicon(100), the shear modulus (G) is approximately 7.96×10¹⁰ N/m². The following is a table of coefficients (β) for various aspect ratios of rectangular beams:

<pre xml:space="preserve" listing-type="tabular"> <!--Greenbook tabular data--> TABLE I______________________________________b/a 1 2 3 4 5 10 ∞______________________________________β 0.1406 0.229 0.263 0.281 0.291 0.312 0.333______________________________________</pre>

With the torsional cantilever illustrated in FIGS. 1 and 2, a force (F_z) acting on the tip 23 in the direction 28 at a distance (L_C) from the torsional support beam 16 produces a torque (T) defined as:

<pre xml:space="preserve" listing-type="equation"> <!--Greenbook equation-->T=F_z L_C Eq. (3)</pre>

The angle of rotation (θ) is the deflection (ΔZ) of the tip in the direction of arrow 28, divided by the length of the cantilever moment arm: ##EQU3## Substituting equations 3 and 4 into equation 2, the effective spring constant (k.sup.θ_z) of the torsional support beam 16 is: ##EQU4## the factor "2" being included because L_T is the length of the torsional support beam 16 from mesa 19 to the cantilever 14.

The preferred beam structure 16 as illustrated in the enlarged view of FIG. 6, includes two parallel segments 84, 85 on opposite sides of the axis 27 of the beam where the torsional force is applied. Both of these segments are beams having a rectangular cross section mounted to the side walls of mesas 19 and 20 and joined by lateral segments 86. It is noted that in the preferred form of the invention, all of the beams have a similar structure, as diagrammatically illustrated in FIG. 2, for example. This structure effectively increases the width (a) of the beam and produces a stiffer cantilever, since increasing the dimension a in Eq. 5 makes the value of k much higher.

FIG. 7 illustrates the relationship of a range of effective spring constant values with respect to cantilever length, as a function of the geometric variables a and L_C, with the dimension b held constant at 10 micrometers. Curves 105 through 108 represent values of total beam width a equal to 1.5 micrometers, 1 micrometer, 0.5 micrometer and 0.25 micrometer, respectively, where the length of the beam L_T is equal to 50 micrometers for curve 105 and 200 micrometers for the remaining curves. These curves indicate that torsional cantilevers fabricated using the SCREAM-I process will achieve spring constants between 10^-3 and 10^-7 N/m. It was found that because of the high aspect ratio (b/a) of the beams, they exhibit no curling or buckling.

The theoretical spring constants for a torsional cantilever are shown in the following table:

<pre xml:space="preserve" listing-type="tabular"> <!--Greenbook tabular data--> TABLE II__________________________________________________________________________Force Deflection Spring Constant Ratio to k.sup.φ_z__________________________________________________________________________F_x acting at tip Δx causing a twisting of angle φ ##STR1## ##STR2##F_y acting at tip Δy ##STR3## ##STR4##F_z acting at tip Δz causing a rotation of angle θ ##STR5## 1F_z acting at center of mass Δz ##STR6## ##STR7##__________________________________________________________________________</pre>

The foregoing table also shows the ratio of the theoretical spring constants to the value k.sup.θ_z, where v is the Poisson's ratio of the material, this ratio being equal to 0.28 for silicon (100). The force (F_x) in the above table acts on the tip 23 in the x direction to cause a deflection along the x axis. Force (F_y) acting at tip 23 produces a deflection in the y direction and a consequent in-plane twisting of the moment arm 12 about support beam 16 through an angle (φ) while force (F_z) acting at tip 23 produces a deflection in the z direction to produce a rotation of angle (θ) about the support beam 16. When the force (F_z) acts at the center of mass; i.e., is directed onto the top of beam 16, there will be a deflection of beam 16 equal to Δz. The spring constants of the cantilever structure 10 for these various forces are illustrated in the table. As long as the length (L_C) of the cantilever arm 12 is longer than the length of the torsional supports (L_T) all other spring constants of the torsional cantilever will be one or more orders of magnitude greater than k.sup.θ_z. The capacitor plates 46 and 54 may be provided to sense relative motion in the z direction. Additional sensors such as comb-type detectors, piezoresistors, mirrors, diodes or transistors may be provided to detect motion of the cantilever in various directions.

Torsional resonators fabricated using the SCREAM technique with k.sup.θ_z equal to about 0.3 N/m have achieved Q values of 10⁵ in a vacuum. A model of the present invention was constructed in accordance with FIG. 1, with the beam width a equal to 1.5 micrometers, the beam height b equal to 12.3 micrometers, the distance (L_T) equal to 50 micrometers and the distance (L_C) equal to 950 micrometers. This structure produced a spring constant of 2.58×10^-2 N/m. Furthermore, the resonant frequency of the torsional cantilever was experimentally measured at 1.4 kHz. The torsional rigidity was then determined, using the following relationship: ##EQU5## where κ is the torsional rigidity and I is the moment of inertia. The known geometry of the device and the densities of the materials permit calculation of the rotational moment of inertia I=2.55×10^-16 kg m². The resulting torsional rigidity is κ=1.97×10^-8 N/m, which means that experimentally k.sup.θ_z =κ/L_C² =2.18×10^-2 N/m.

FIG. 8 illustrates a modification of the cantilever device of FIGS. 1 and 2, wherein the counterweight 26 is replaced by a second cantilever moment arm 120 which is a duplicate of moment arm 12 and is coplanar, but extending on the opposite side of support beam 16. The cantilever moment arm 120 includes segments 122, 124, 126, and 128 which correspond to segments 60, 64, 68, and 72 of moment arm 12, with the cantilever structure extending over electrode 54' on the floor 38 of cavity 34. The symmetric design of FIG. 8 provides improved results for applications such as in a scanning force microscope, since the moment arms of the two cantilevers about support beam 16 may be more precisely balanced. However, the asymmetric design of FIGS. 1 and 2 may provide improved results for some sensor applications such as in an accelerometer. As with FIGS. 1 and 2, the electrodes 54 and 54' beneath the structure are used to move the cantilever in the vertical, or z, direction or to detect motion, or both.

A still further embodiment of the invention is illustrated in FIGS. 9 and 10, wherein the cantilever device 10 of FIGS. 1 and 2 is provided with electrodes adjacent the torsional support beam 16 for controlling twisting of the beam under the torsional forces applied by the cantilever moment arm 12 and the counterweight 26. In this illustration, the relative positions of the arm 12 and counterweight 26 with respect to beam 16 are reversed. As illustrated, a first pair of electrodes 140, 142 is placed adjacent end 30 of beam 16 while a second pair of electrodes 144, 146 is placed adjacent end 32 of beam 16. As the support beam 16 is twisted under a torsional force, as illustrated in dotted lines at 16' in FIG. 10, the upper edge 148 of beam 16 approaches electrode 142 and the lower edge 150 approaches electrode 140. A voltage applied to the electrodes 140 and 142, such as the voltage V relative to the voltage on beam 16, will attract the respective edges 148 and 150 of beam 16, causing the beam to twist further, so that the applied voltage can be used to reduce the spring constant of the cantilever. A variable voltage allows adjustment of the spring constant.

It will be understood that the voltage may be applied to the electrodes 140, 142, and 144, 146 by way of integrated circuits fabricated on the substrate 18, such as circuits generally indicated at 152 and 154 in FIG. 9, connected by way of conductors 156, 158, and 160, 162, respectively. These electrodes and conductors may be fabricated in accordance with the SCREAM-I process described above.

It has been found that the planar configuration of the cantilever moment arms 12 and 120 illustrated in the preceding figures may be subject to some in-plane twisting. In order to sense such twisting, a plurality of comb-type sensor sets 170, 172, 174, and 176 may be provided, as illustrated in FIG. 11. In one embodiment, each of the sensor sets, such as set 170, may include a plurality of stationary finger electrodes 180 mounted in cantilever fashion to a mesa 181 on the substrate and located within the cavity 34, which contains the cantilever moment arms 12 and 120. Alternatively, the stationary electrodes 180 may be in the form of mesas, or islands, extending upwardly from the floor 38 of cavity 34. Movable finger electrodes 182 are mounted on the cantilever moment arm 12 for motion with the cantilever arm and extend between corresponding stationary electrodes 180 to form interleaved electrode fingers. The fingers may be metal coated to form capacitor plates to sense the motion of the cantilever arms 12 and 120 with respect to the stationary fingers. The illustrated sensors detect motion, both within the plane of the cantilevers and out of the plane of the cantilevers. Further, upon application of suitable voltages; for example, through an active feedback circuit (not shown) on substrate 18, motion of the cantilevers can be damped or enhanced to compensate for the twisting of the support beam 16. The comb-type capacitor sets 172, 174, and 176 are similar to set 170.

A still further embodiment of the invention is illustrated in FIG. 12, wherein the electrodes 54, 54' mounted on the floor of the cavity 34 in which the cantilever structure 10 is located are omitted, and in their place are provided longitudinally extending comb-type sensors or actuators interacting with the cantilever moment arms. In this embodiment, a comb-type torsional cantilever device 200 is fabricated within cavity 34 in substrate 18, again using the SCREAM-I process described above. The cantilever device 200 is mounted on a torsional support beam 16 which preferably is integral with the substrate 18 and is mounted on mesas 19 and 20 in cavity 34, in the manner described above with respect to the device of FIG. 1, for example. The cantilever device 200 includes a pair of narrow elongated moment arms 202 and 204 which are spaced from, and are suspended above, the floor 38 of cavity 34. Upon application of a vertical force, the arms are urged in a direction perpendicular to the plane of the cantilever 200, as described above, and since the moment arms 202 and 204 are mounted on opposite sides of lateral torsional support beam 16, unequal moments will cause the support beam 16 to twist.

The cantilever moment arm 202 extends from a laterally-extending base region 206 which is mounted on support beam 16 by a plurality of connector beams 208 for rotational movement about the axis of the support beam. The base region 206 carries a plurality of longitudinally-extending, spaced parallel fingers 220 in the form of high aspect ratio beams. The fingers 220 extend above, and are released from, floor 38 and thus are movable with respect to it, are parallel to the longitudinal axis of the moment arm 202, are mounted for rotational movement about beam 16, and are coplanar with the moment arm.

Interleaved with the fingers 220 are a plurality of longitudinally-extending stationary fingers 222 which are mounted on mesas 224 and 226 in cavity 34. Fingers 222 extend in cantilever fashion parallel to, and between, adjacent fingers 220 and preferably are coplanar therewith. Alternatively, the stationary fingers 222 may be in the form of mesas upstanding from floor 38 of cavity 34 and extending between fingers 220.

For symmetry, two sets 228 and 230 of interleaved fingers are provided for moment arm 202 and two sets 232 and 234 of similarly interleaved fingers 220' and 222 are provided for moment arm 204, which is similarly mounted for rotation about torsional beam 16. In one embodiment, the interleaved fingers are fabricated with metal layers to provide opposed capacitor electrodes on adjacent fixed and movable fingers. These electrodes are connected to external circuitry by way of mesas 19 and 20 for the movable electrodes and by way of mesas 224, 226 and 224' and 226' for the stationary electrodes. Relative motion of movable capacitor electrodes on fingers 220 and 220' with respect to the stationary capacitor electrodes on fingers 222 and 222' respectively, can be measured to detect vertical motion of a tip mounted on either of the cantilever arms 202 and 204, in the manner described above. Similarly, by selectively applying voltages between adjacent electrodes, the arms 202 and 204 can be moved, or their response characteristics varied.

Modifications of the comb-type drive of FIGS. 11 and 12 are illustrated in FIGS. 13-15, wherein moveable and fixed interleaved fingers 240 and 242, which correspond to fingers 220 and 222 in FIG. 12, are fabricated by the process of U.S. Pat. No. 5,628,917 described above. This process does not result in metal-coated electrode fingers, but instead permits fabrication of partially oxidized released, or movable, silicon fingers, such as the partially oxidized fingers 240 in FIG. 13, having their upper portions 244 oxidized, with the lower portions 246 remaining as silicon. Alternatively, as illustrated in FIG. 14, the upper portions 248 of the fixed silicon fingers 242 can be oxidized, with the lower portions 250 remaining silicon. A voltage V may be applied across the silicon portions of the adjacent fingers to produce an asymmetric electric field between them which will result in relative motion of the fingers. As will be explained in greater detail below, the application of a negative voltage to the stationary fingers 242 and a positive voltage to fingers 240 in FIG. 13 will result in an asymmetric field which will produce an upward force on the movable fingers, while the same voltage applied to the device of FIG. 14 will result in a downward force on the movable fingers.

In the embodiment of FIG. 15, the interleaved fingers are provided with alternating oxidized and non-oxidized segments, the movable silicon fingers 240 including oxidized (silicon dioxide) segments 252, and the fixed silicon fingers 242 including oxidized (silicon dioxide) segments 254. The oxidized segments on each finger are aligned with non-oxidized segments on adjacent fingers, so that by controlling the polarity of the voltages applied to the individual fingers, either upward or downward motion of the movable fingers can be achieved.

FIG. 16 illustrates another embodiment of the invention wherein two cantilever moment arms 260 and 262 are mounted within the cavity 34 in substrate 18, in the manner described above. In this embodiment, cantilever arms 260 and 262 both incorporate longitudinal interleaved sets of capacitor plates of the type illustrated in FIG. 12, cantilever arm 260 including capacitors sets 264 and 266, and cantilever arm 262 incorporating capacitor sets 268 and 270 in place of the underlying electrodes utilized in previous embodiments. These capacitive electrode sets are used to sense the vertical motion of the cantilever arms 260 and 262, in the manner previously described, when the arms pivot about support beam 16 in response to the applied force or when both beams move in the same direction to deflect the beam 16. In addition, the device of FIG. 16 incorporates sets of stabilizing comb capacitors to prevent or to compensate for in-plane twisting, cantilever arm 260 including stabilizing actuator sets 272 and 274, and cantilever arm 262 utilizing stabilizer actuator sets 276 and 278. The stabilizer actuators preferably are capacitive, in the manner previously described.

FIG. 17 is a diagrammatic illustration of one use of the torsionally-mounted cantilever device of the invention in an atomic force microscope. As illustrated, the cantilever device 290, which may be any one of the cantilever devices described above, is mounted adjacent to the surface 292 of a sample 294 that is to be scanned. The sample is mounted on a scanning table 296 which may be driven, as by conventional piezoelectric electric drivers, in an XY plane beneath and parallel to the cantilever 290. The sample should also be adjustable in the Z direction to move it into proximity with a sensor tip 298 carried by the cantilever. When the tip is positioned very close to the surface of sample 294, the tip will interact with the material of the surface to produce deflection of the cantilever 290, as is known in the art of atomic force microscopes. The deflection of the cantilever may be detected by sensor 300, which may be any of the actuator/sensor devices described above, to produce an output signal through a feedback loop 302 to control the operation of the scanner 296. The cantilever of the present invention is extremely sensitive and thus allows measurements of extremely small forces with great accuracy.

Instead of mounting the sample for motion, or in addition to doing so, the cantilever device itself can be mounted for motion in an XY plane, with the torsional movement of the cantilever producing motion of the sensor tip 298 in the Z direction. Such an xy mounting is illustrated by the drawing representing a photomicrograph in FIG. 18 to which reference is now made. In this embodiment, a cantilever structure 310 is mounted on a torsional support beam 312 in the manner described above. The outer ends of beam 312 are mounted on a movable frame 314 which is generally rectangular, having four sides, with each side carrying a moveable comb-type sensor/actuator. Thus, for example, an actuator 315 is located at frame side 316 and includes movable capacitive fingers 318, mounted on the frame. Corresponding stationary capacitive fingers, such as the fingers 320 for actuator 315, are mounted on an outer frame 322 and are interleaved with movable fingers 318. The outer frame member 322 is in turn secured by spring arms 324 to a fixed substrate. Similarly, an actuator 330 is located on the side of frame 314 which is opposite to actuator 315, so that upon energization of either actuator 315 or 330 the torsional cantilever device 310 will be moved along its longitudinal axis, in a direction perpendicular to support beam 312 and which may be referred to as the x-axis, or x direction.

Actuators 332 and 334 are located on opposite sides of frame 314 at the ends of support beam 312, and when energized tend to move the frame 314 along the axis of support beam, in a direction which may be referred to as the y-axis or Y direction. Torsional motion of cantilever 310 about support beam 312 provides motion of the sensor tips carried by the cantilever in a direction perpendicular to the XY plane to provide Z-direction motion of the tips.

Although FIG. 18 illustrates just a single cantilever mounted within a frame movable in the X and Y directions, the structure can be expanded to provide an array of cantilevers, in the manner illustrated in FIG. 19. As there illustrated, a 10×10 array of torsional cantilevers 340 are mounted in a 1 millimeter by 1 millimeter square frame 342, with the cantilevers being spaced at 100 micrometer intervals. Each cantilever is mounted on a corresponding torsional support beam, such as beam 344 of cantilever 340, between parallel frame elements, such as the frame elements 346, which are parallel to the X axis of the array. The individual cantilever arms are located between spaced, parallel Y-axis frame elements, such as elements 348. The entire structure is fabricated by the SCREAM process described above, and is released from the underlying substrate for motion in the x-y plane. Suitable spring arms, such as those described above with respect to FIG. 18, may be provided to secure the structure to the substrate.

On each of the sides of frame 342 are one or more actuators which may be comb-type capacitive frame driver sets, such as those illustrated at 350 and 352, each of which contains movable capacitor fingers mounted on movable frame 342 and stationary capacitor fingers mounted on a stationary frame or substrate 354. If desired, frame 354 may carry multiple sets of stationary comb capacitor fingers which engage corresponding fingers carried by extensions of frame 342. Thus, for example, the stationary frame 354 and the movable frame 342 may carry comb capacitor driver sets 356, 358, 360, and 362. These additional sets of comb capacitors increase the distance which the frame 342 can be moved in the X-axis direction and increase the precision of operation so that the cantilevers 340 can be precisely positioned. Similar comb capacitor actuators, or drivers, are provided at each of the four sides of the array, the driver sets indicated at 364 cooperating to provide motion along the X-axis with similar structures (not shown) on the remaining two sides of the array providing motion along the Y axis.

Each of the sensor tips on the individual cantilevers 340 are connected to suitable switching and control logic circuits, illustrated generally at 366 and 368. The connections are by way of the frame elements 346 and 348 in the manner described with respect to the movable stage device described in U.S. Pat. No. 5,506,175 to Zhang et al. As there described, the frame elements are constructed of multiple interconnected parallel beams with oxidized segments at selected locations to provide electrical paths between the switching and control circuits 366 and 368 and control capacitors and sensors for corresponding individual cantilevers.

A major advantage of the array of FIG. 19 is that an area 1 mm×1 mm can be scanned by moving individual tips only 100 micrometers along their respective x and y axes. This allows very rapid scanning of a large area without the need for large scale motion.

Although the various capacitor structures described above may be used for driving or for sensing the movement of the cantilever device of the present invention, motion sensing can also be accomplished by piezoresistor sensors utilized in place of, or in addition to capacitor sensors, if desired. FIGS. 20 and 21 illustrate such piezoresistor sensors for the cantilever arm 12 of FIG. 1, although it will be apparent that similar sensors may be used for any of the torsional cantilever devices described above. Accordingly, in FIG. 20, the moment arm 12 is shown as connected to the torsional support beam 16 by connector beams 76-79 and the counterbalance 26 is shown as being connected to the beam 16 by connectors 80-83, all as described with respect to FIG. 1. The beam 16 is connected at its ends 30 and 32 to mesas 19 and 20, respectively.

In accordance with embodiment of FIGS. 20 and 21, a piezoresistor sensor is built into the torsional support beam to measure the deflection of the cantilever. The piezoresistive effect is the change in resistance of a conductor when it is subjected to a mechanical strain, and in this case, the resistor is defined by implanting an n-type region into a p-type substrate (or in the alternative, by implanting a p-type region into an n-type substrate) in the region of the beam 16 and mesas 19 and 20 prior to fabrication of the cantilever device. The device is then fabricated using the SCREAM-I process, as described above, with the torsional support beam 16 being located in the implanted region. The top surface of the beam and of the mesas is covered with an oxide layer 380, and vias 382 and 384 are opened through the oxide layer to expose the surface of the n-type substrate silicon on the mesas 19 and 20, respectively. Another implant through these vias then defines highly doped regions 386 and 388 to provide contact areas. Aluminum is then sputtered onto the structure and patterned to provide aluminum contacts 390 and 392 in the vias, and these contacts are then connected to external circuitry, as by way of wires (not shown) bonded to the aluminum contacts 390 and 392 and to corresponding contacts on sensor circuitry located on the adjacent substrate. The beam 16 then acts as a resistor connected between the contacts 390 and 392.

When a force interacts with the torsional cantilever, a torque is generated about the central axis of the torsional support beam 16. The stress in the beam produces a change in its resistance, and this change can be detected by incorporating the beam resistor in a Wheatstone bridge in the circuitry carried on the substrate. The measured resistance change can be directly related to the amount of deflection of the cantilever, and thus to the force which generated the torque.

Another stress-sensitive sensor, which is based on the piezojunction effect, is illustrated in FIGS. 22 and 23. When silicon devices, such as diodes and transistors, are subjected to stress, the characteristics of these devices are affected; more particularly, when a stress in applied to a pn junction, the band gap of the junction decreases and the diffusion length increases. This increases the saturation current and leads to a higher forward current for the same forward bias voltage. In the embodiment illustrated in FIGS. 22 and 23, advantage is taken of this effect by incorporating a diode into the torsional support beam 16 of the torsional cantilever device 10 of FIG. 1. The deflection of the cantilever is then monitored by the change in the current of the diode.

In FIGS. 22 and 23, a pair of sensor diodes are formed by implanting n+ regions, such as regions 400 and 402, in a p-substrate silicon at the junctions 30 and 32 of the torsional support beam 16 with fixed mesas 19 and 20. Alternatively, a p+-type region may be implanted into an n-type substrate silicon. After formation of the beam 16 and the mesas 19 and 20 using the SCREAM-I process described above, vias 404 and 406 are opened in the top oxide layer 408 of beam 16 and mesas 19 and 20 to permit contact to be made to the implanted region. This contact is obtained by sputtering of aluminum at 410 and 412 on the mesas and over the doped regions exposed by the vias 404 and 406.

A second contact to the diode is by way of a p+ region 414 and an aluminum contact 416 located on the adjacent substrate 18 at a location near to the mesas 19 and 20. As illustrated in FIGS. 22 and 23, the two diodes are located at the junctions of the torsional support beam 16 with the fixed support for the beam. When a force interacts with the torsional cantilever, a torque is generated about the central axis of the torsional support beam 16. The stress in the beam is maximized at the junctions 30 and 32, and this stress acts on the diodes to cause a change in the current in each diode. The measured current change can be directly related to the amount of deflection of the cantilever, and subsequently to the force which generated the torque. The aluminum contacts are connected as by wire leads bonded to the contacts, to corresponding contacts in adjacent circuits to provide the requisite measurements.

The comb-type actuator/sensor devices utilized in the present invention have been described as being fabricated from high aspect ratio beams all of the same height. As discussed above with respect to FIGS. 13 and 14, it may be desirable to provide comb-type actuators fabricated to have beams with different effective heights in order to obtain asymmetric electric fields between adjacent interleaved fingers in order to produce vertical forces and controlled relative motion between adjacent fixed and movable fingers. This asymmetric field provides an actuator that is capable of producing vertical (Z axis) motion with respect to the plane of the actuator in a structure such as a cantilevered moment arm. The asymmetry increases the amount of vertical force available for actuator of a movable structure, controls the total amount of out-of-plane static deflection, and provides control of vertical motion in devices such as those described above without the need for a ground plane, or conductive electrode, on the surface of the substrate below the movable structure.

Interdigitated electrode capacitive actuators such as those described above take advantage of the electrostatic comb drive levitation effect which is illustrated in FIG. 24. Thus, for example, interdigitated fixed and movable fingers 180 and 182 described with respect to FIG. 11 and illustrated and cross sectioned in FIG. 24 may be energized by applying a voltage V to the fixed electrodes. The substrate 18 is grounded, as is the movable electrode 182, producing the electric field lines 430 extending between the adjacent side walls of the fixed and movable electrodes, field lines 432 extending between the top surfaces of the fixed and movable electrodes, and field lines 434 extending between the bottoms of the ungrounded fixed electrodes 180 and the substrate 18. As illustrated, the electric fields 430, 432, and 434 produce a vertically asymmetric electric field which produces a vertical force 436 on the movable electrode. This force causes the movable electrode to move away from the substrate and can be used to generate static displacements of the movable fingers, and thus of the cantilever by applying a constant voltage, or to generate vibrational excitation of the cantilever by applying a varying voltage.

To simulate the torque generated at the support beam 16 by a cantilever structure utilizing interdigitated capacitive electrodes, the electrode structure of FIG. 24 was utilized in a 3-D finite element/boundary element electrostatic simulator. For the geometry of an electrode structure wherein the width of a beam (a') was 1 micrometer, the distance (d') between adjacent electrodes was 2 micrometers, the height of an electrode beam (b) was 10 micrometers, and the distance to the substrate (e) was 5 micrometers, and with an applied voltage (V) of 1 volt, the resulting torque as a function of angular displacement of the cantilever at the support beam 16 was plotted and resulted in curve 440 of FIG. 25. It was found that the equilibrium position of the cantilever occurred at an angular displacement (θ₀) equal to 0.012 radians.

In an effort to increase the static deflection of the cantilever, different electrode configurations were studied and it was found that a configuration where the movable electrodes had heights different from the heights of the fixed electrodes exhibited the greatest increase in deflection. Such a configuration is illustrated in FIGS. 26 and 27 wherein an actuator 450 includes a plurality of fixed fingers 452, 454, 456, etc. mounted on a fixed substrate or mesa portion 458. The fixed fingers have a height (b) and a width (a') similar to that of the fingers 180 discussed above with respect to FIG. 24.

Movable fingers 460, 462, 464 are mounted on a movable structure such as a cantilever moment arm 466, with the fingers being interdigitated between the fixed fingers 452, 454, and 456. The width of the movable fingers 460, 462, and 464 are the same as the widths of the fixed fingers, but in this case the height (b') of the movable fingers differs significantly from that of the fixed fingers. It will be understood that the height difference could be reversed, with the movable fingers being greater in height than the fixed fingers, if desired.

As illustrated in FIG. 27, the change in relative heights of the fixed and movable fingers changes the pattern of the electrostatic fields, and increases the asymmetry. A plot of the levitation torque as a function of angle for the configuration of FIG. 27, where all of the parameters are the same as those of FIG. 24, except that the height (b) of the fixed fingers was 1 micrometer greater than the height (b') of the movable fingers. A plot of this function is illustrated by curve 464 in FIG. 28. It was found that the equilibrium position for this configuration occurred θ₀ equal to 0.025 radians.

The region of interest in these curves is the approximately linear region around T_lev =0. It is approximately by ##EQU6## where V is the potential applied to the fixed electrodes, θ₀ is the angle at which T_lev =0 (the equilibrium angle), and γ.sub.θ is the drive capacity.

The total torque acting on the cantilever, or moment arm, includes the levitation torque provided by the interdigitated electrodes and the passive restoring torque provided by the torsional support beam 16. The static deflection of the cantilever is then found by solving

<pre xml:space="preserve" listing-type="equation"> <!--Greenbook equation-->T_net =T_lev -T_spring Eq. 8</pre>

where T_net is the net torque acting on the cantilever and T_spring is the restoring torque provided by the torsional support beam. With T_spring =k.sub.θ θ, the value of θ is determined as: ##EQU7##

The tip of the cantilever is located a distance (L_C) from the axis of rotation at beam 16. Therefore, the static (z) deflection of the tip is given by ##EQU8##

A plot of the static deflection as a function of the applied voltage (V) is shown in FIG. 29 at curve 470. The deflection asymptotically approaches a value equal to the equilibrium angle (θ₀) multiplied by the length of the cantilever (L_C).

The equilibrium angle is the most important parameter in the determination of how far the cantilever will move statically. The drive capacity and the torsional stiffness cooperate to control how quickly the deflection approaches the asymptotic limit.

In addition to the dynamic response of the torsional cantilevers, the out-of-plane static deflection of the structure of FIG. 27 was measured under scanning electron microscope (SEM) observation. The sample was tilted in the SEM, DC voltages were applied to one set of fixed interdigitated electrodes, and the resulting deflection was recorded on videotape. The tape was analyzed later on a computer using structures of known height for calibration. The results of this measurement are illustrated by curves 472 and 474 in FIG. 30. Curve 472 shows the static deflection of a torsional cantilever array as a function of applied voltage for elements having a width (a) of 0.50 μm, while curve 474 is for elements having a width of 1 μm.

The curves shown in FIG. 30 are theoretical curves generated by Eqn. (10). The parameters for the a=1 μm torsional cantilever are: θ₀ =0.019 rad., γ.sub.θ =7.86×10^-14 N m/V², and k.sub.θ =1.88×10^-8 N m/rad. For the a=0.50 μm the parameters are: θ₀ =0.011 rad., γ.sub.θ =7.56×10^-14 N m/V², and k.sub.θ =1.64×10^-9 N m/rad.

FIG. 30 displays the effect of scaling the width (a) of the torsional support beams. Both static response curves indicate that 0.7 μm of out-of-plane deflection can be achieved when using one set of fixed electrodes. Using both sets of electrodes, the total range of deflection is ±0.7 μm. However, the voltage necessary to obtain such a deflection is about 45 V for the device with a=0.50 μm and about 70 V for the device with a=1 μm. Since the width (a') and gap (d') of the interdigitated electrodes were not scaled, the drive capacity (γ.sub.θ) remained constant as the curve fit parameters show. Only the torsional stiffness of the cantilevers was scaled. The curve fit values compared to those obtained theoretically exhibit reasonable agreement, and approximately an order of magnitude decrease in stiffness was observed as the torsional support width was scaled downward by a factor of 1/2.

The simulation illustrated in FIG. 28 indicated that the equilibrium angle (θ₀) would increase from 0.012 radians to 0.025 radians with a 1 μm difference in the electrode heights. Such a configuration of the electrodes was fabricated, and the out-of-plane static deflection response of these devices is shown in FIG. 31 at curves 476 and 478.

A curve fit of Eq. 10 was performed. The parameters for Device #1 (curve 476) are: θ₀ =0.029 rad., γ.sup.θ =5.46×10^-14 N m/V², and k.sub.θ =1.58×10^-8 N m/rad. For Device #2 (curve 478) the parameters are: θ₀ =0.029 rad., γ.sup.θ =5.00×10^-14 N m/V², and k.sub.θ =1.70×10^-9 N m/rad. These cantilevers were fabricated with a=0.50 μm and this is reflected in the stiffness closely matching that of the 0.50 μm device in FIG. 30. These devices achieved 1.1-1.2 μm of out-of-plane deflection with 30 V, whereas the device of FIG. 30 achieved only 0.6 μm with 30 V. Thus, the difference in electrode height allowed the cantilever to actuate an additional 0.5 μm.

Although the present invention has been described in terms of numerous embodiments, it will be apparent that variations and modifications may be made without departing from the true spirit and scope thereof as set forth in the following claims.